SCHUNK ROTA-S flex User instructions

Translation of Original Operating Manual
Manual Lathe Chucks
ROTA-S flex
Assembly and Operating Manual

Imprint
2 06.00 | ROTA-S flex | Assembly and Operating Manual | en | 0889139
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 0889139
Version: 06.00|14/04/2022|en
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions.
Ask us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
Table of Contents
1 General.................................................................................................................... 5
1.1 Warnings .............................................................................................................. 5
1.2 Applicable documents .......................................................................................... 6
2 Basic safety instructions........................................................................................... 7
2.1 Intended use......................................................................................................... 7
2.2 Not intended use.................................................................................................. 7
2.3 Notes on particular risks....................................................................................... 7
2.4 Notes on safe operation ..................................................................................... 10
2.4.1 Constructional changes, attachments or modifications .........................13
2.5 Personnel qualification....................................................................................... 13
2.6 Organizational measures.................................................................................... 14
2.7 Using personal protective equipment ................................................................14
3 Warranty ................................................................................................................15
4 Torques per screw ..................................................................................................16
5 Scope of delivery ....................................................................................................17
6 Technical data.........................................................................................................18
6.1 Chuck data.......................................................................................................... 18
6.2 Clamping force / speed diagrams....................................................................... 19
6.3 Calculations for clamping force and speed.........................................................21
6.3.1 Calculation of the required clamping force in case of a given rpm ........22
6.3.2 Calculation example: required initial clamping force for a given speed
................................................................................................................24
6.3.3 Calculation of the permissible speed in case of a given initial clamping
force........................................................................................................25
6.4 Grades of Accuracy............................................................................................. 26
6.5 Permissible imbalance........................................................................................ 26
7 Attachment of the entire manual chuck..................................................................27
7.1 Handling prior to attachment............................................................................. 27
7.2 Preparing the chuck attachment ........................................................................ 27
7.3 Assembly of the entire manual chuck ................................................................27
8 Function .................................................................................................................28
8.1 Handling and jaw change ................................................................................... 28
8.2 Important notes on the ROTA-S plus or ROTA-S plus 2.0 manual chuck............29
8.3 Checking the ROTA-S plus or ROTA-S plus 2.0 manual chuck............................. 29
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Table of Contents
9 Maintenance ..........................................................................................................30
9.1 Disassembling and assembling the chuck........................................................... 30
9.2 Jaw change ......................................................................................................... 30
9.3 At least once a month ........................................................................................ 31
9.4 In the case of decreasing clamping force or after approx. 200 operating hours
............................................................................................................................ 31
10 Spare parts ROTA-S flex ..........................................................................................32
11 Assembly drawing...................................................................................................33
12 Spare parts ROTA-S plus 2.0....................................................................................34
13 Assembly drawing...................................................................................................35
14 Spare parts ROTA-S plus..........................................................................................36
15 Assembly drawing...................................................................................................37
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General
1 General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual,
especially the chapter “Basic safety notes”.}2 [/7]
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
1.1 Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
CAUTION
Material damage!
Information about avoiding material damage.
WARNING
Warning about hand injuries
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General
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WARNING
Warning about hot surfaces
1.2 Applicable documents
General terms of business
Katalogdatenblatt des gekauften Produkts
Calculation of the jaw centrifugal forces
("Technology" chapter in the lathe chuck catalog)
The above mentioned documents can be downloaded at
www.de.schunk.com.

Basic safety instructions
2 Basic safety instructions
Improper handling, assembly and maintenance of this product
may result in risks to persons and equipment if this operating
manual is not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only original SCHUNK spare parts may be used.
2.1 Intended use
The chuck is used to clamp workpieces on machine tools and other
suitable technical facilities, paying particular attention to the
technical data specified by the manufacturer. The technical data
specified by the manufacturer must never be exceeded.
The product is intended for industrial use.
Intended use also means that the user has read and understood
this operating manual in its entirety, especially the chapter “Basic
safety notes”.
The maximum RPM of the chuck and the required clamping force
must be determined by the user for the respective clamping task
based on the applicable standards and technical specifications of
the manufacturer.
(See also “Calculations for clamping force and RPM” in the chapter
“Technical data”). }6.1 [/18]
2.2 Not intended use
A not intended use of the product is for example:
• It is used as a press, a punch, a toolholder, a load-handling
device or as lifting equipment.
• the product is used for unintended machines or workpieces.
• the technical data is exceeded when using the
product. }6.1 [/18]
• if workpieces are not clamped properly, paying particular
attention to the clamping forces specified by the manufacturer.
• if it is used in working environments that are not permissible.
• if the product is operated without a protective cover.
2.3 Notes on particular risks
This product may pose a danger to persons and property if, for
example:
• It is not used as intended;
• It is not installed or maintained properly;
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Basic safety instructions
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• The safety and installation instructions, local applicable safety
and accident prevention regulations or the EC Machinery
Directive are not observed.
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the lathe chuck fails because the technical data have
been exceeded and a workpiece is released or parts fly off
•The technical data specified by the manufacturer for using the
lathe chuck must never be exceeded.
•The lathe chuck may only be used on machines and facilities
that fulfill the minimum requirements of the EC Machinery
Directive; specifically, they must have effective technical
measures to protect against possible mechanical hazards.
DANGER
Possible risk of fatal injury to operating personnel from clothing
or hair being caught on the lathe chuck and being dragged into
the machine
Loose clothing or long hair may become caught on projecting
parts of the lathe chuck and be drawn into the machine.
•The machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
•Always wear tight-fitting clothing and a hairnet when working
on the machine and the lathe chuck.
DANGER
Possible risk of fatal injury to operating personnel due to loss of
clamping force as a result of temperature changes between the
clamping procedure and machining due to loss of workpiece!
•If the chuck jaws are expected to penetrate the workpiece
during the clamping procedure and if a temperature change
occurs between the clamping procedure and machining, it is
imperative that the lathe chuck is re-tensioned before
machining.
•The larger the clamping diameter, the difference in the linear
expansion coefficient of the workpiece compared to steel and
the temperature range, the greater the loss of clamping force.

Basic safety instructions
DANGER
Possible risk of fatal injury to operating personnel due to loss of
clamping force as a result of the time period between the
clamping procedure and machining due to loss of workpiece!
•If the time between the clamping procedure and machining is
longer than 8 hours, it is imperative to re-tension before
machining.
WARNING
Risk of injury due to dropping the chuck during transport,
installation or removal.
•Take special care in the danger zone when transporting,
installing or removing the chuck.
•Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.
WARNING
Risk of injury by catapulted brass cover caps (accessory) of the
clamping bolt in case of rotation of the chuck.
The brass cover caps (accessory) of the clamping bolt must only
be used for stationary use of the chuck.
CAUTION
Danger of slipping and falling in case of dirty environment
where the chuck is used (e.g. by cooling lubricants or oil).
•Ensure that the working environment is clean before starting
assembly and installation work.
•Wear suitable safety shoes.
•Follow the safety and accident-prevention regulations when
operating the chuck, especially when working with machine
tools and other technical equipment.
CAUTION
Danger of limbs being crushed by opening and closing of the
chuck jaws during manual loading and unloading or when
replacing moving parts.
•Do not reach between the jaws.
•Wear safety gloves.
•Observe the safety and accident prevention regulations during
operation of the chuck, especially in connection with
machining centers and other technical equipment.
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Basic safety instructions
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CAUTION
Risk of burns due to workpieces with high temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Danger of damage due to incorrectly selected clamping position
of the clamping jaws to the workpiece.
An incorrectly selected clamping position of the clamping jaws to
the workpiece can result in damage to the base and top jaws.
•Make sure that the workpiece clamping is concentric.
•In the case of a chuck with a quick-change jaw system the top
jaws must not protrude radially beyond the base jaws used.
Exception: The supporting jaw variant 3 protrudes beyond the
chuck base jaw due to the construction of the jaw. In this
case, the T-nuts must always be inserted completely into the
groove of the chuck base jaw.
CAUTION
Hazard from vibration due to imbalanced rotating parts and
noise generation.
Physical and mental strains due to imbalanced workpieces and
noise during the machining process on the clamped and rotating
workpiece.
•Ensure the chuck's axial and concentric runout.
•Check options for remedying imbalances on special top jaws
and workpieces.
•Reduce the speed.
•Wear hearing protection.
CAUTION
Excessive lubrication may lead to functional defects (stiffness)
when changing jaws or in the release mechanism.
•Disassemble the chuck and remove the excess grease.
•For lubrication observe the chapter maintenance.
2.4 Notes on safe operation
• Do not start the machine spindle until the workpiece is clamped
and the spanner wrench has been removed from the chuck.
• Only operate the lathe chuck when all protective equipment has
been fitted and is in full working order.

Basic safety instructions
• Check the lathe chuck at least once per shift for externally
visible damage and faults.
Functional test
After installation of the lathe chuck, its function must be checked
prior to start-up:
•Clamping force! At max. torque, the clamping force specified
for the chuck must be reached.
•Indicator pin! Never clamp or switch on the lathe when the
indicator pin is protruding. (Golden pin on the chuck's shell).
•Jaw lock! The spindle can only be turned when all the chuck
jaws have been fitted into the T-slot. This prevents the wedge
bars from being brought into the working position without
chuck jaws.
Speed of rotation
DANGER
Possible risk of fatal injury to operating personnel if the chuck's
top speed is exceeded and a workpiece is released or parts fly
off.
If the machine tool or technical equipment can reach a higher
speed than the chuck's top speed, a reliable speed limiter must
be installed and proof must be provided that the speed limiter is
effective.
WARNING
Vibrations caused by the processing can result a loss of
clamping force. Risk of injury due drop out of the workpiece.
Manually operated chucks can lose clamping force because of
vibration which is caused by the processing of the workpiece.
•Tighten the chuck regularly during processing to compensate
the loss of clamping force due to vibration.
Maintenance instructions
The manual chuck's reliability and safety can only be guaranteed if
the operator complies with the manufacturer's maintenance
instructions.
• For lubrication, we recommend our tried and tested special
grease, LINOMAX plus. Unsuitable lubricants can have a
negative impact on the functioning of the chuck (clamping
force, coefficient of friction, wear characteristics).
(For product information about LINOMAX plus, see the
"Accessories" chapter of the SCHUNK lathe chuck catalog or
contact SCHUNK.)
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Basic safety instructions
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• Use a suitable high-pressure grease gun to ensure that you
reach all the greasing areas.
• To ensure correct distribution of the grease, move the lathe
chuck to its end positions several times, lubricate again, and
then check the clamping force.
• We recommend checking the clamping force using a clamping
force tester before starting a new production run and between
maintenance intervals. *Optimum safety can only be
guaranteed through regular checks*.
• The clamping force should always be measured with the chuck
in the same condition as it is used in for the current clamping
application. If top jaws with clamping steps are used, measuring
must be performed in the same step as for the respective
clamping task. In the event of high operating speeds, clamping
force losses must be accounted for due to the centrifugal force
acting on the chuck jaws. In this case the value of the operating
clamping force should be measured dynamically.
• Move the lathe chuck through to its end position several times
after 500 clamping strokes, at the latest. (This moves the
lubricant back to the force transmission surfaces so that the
clamping force is retained for longer).
Safety notes for servicing
Follow all the applicable legal standards for health and safety
during servicing. Use suitable personal protective equipment,
especially protective gloves, goggles, and safety boots - paying
particular attention to the operating system and hazard
assessment.
Immediately report any changes including operational behavior to
the competent units/persons; if necessary, immediately shut down
and secure the machine on which the lathe chuck is mounted. Do
not start up the machine that the chuck is mounted on again until
the malfunction has been eliminated.
DANGER
Possible risk of fatal injury to operating personnel due to
toolholder failure if the maintenance and servicing instructions
for the toolholder are disregarded
The servicing instructions specified by the manufacturer must be
complied with to ensure safe operation of the chuck.
Work must be carried out by qualified specialist personnel with
the relevant safety training.
Use of special chuck jaws
When using special chuck jaws, please observe the following rules:

Basic safety instructions
• The chuck jaws should be designed to be as light and as low as
possible. The clamping point must be as close as possible to the
chuck face (clamping points at a greater distance lead to greater
surface pressure in the jaw guidance and can significantly
reduce the clamping force).
• Do not use welded jaws.
• If for constructional reasons the special chuck jaws are heavier
than the top jaws assigned to the clamping device, greater
centrifugal forces must be accounted for when defining the
required clamping force and the recommended speed.
• Screw the jaw mounting bolts into the bore holes furthest
apart.
• The maximum recommended speed may only be operated in
conjunction with the maximum clamping force and only with
the lathe chuck in optimum, fully functioning condition.
• If the chuck is involved in a collision, it must be subjected to a
crack test before using it again. Damaged parts must be
replaced with original SCHUNK spare parts.
• Renew the chuck jaw mounting bolts if there are signs of wear
or damage. Only use bolts with a quality of 12.9.
2.4.1 Constructional changes, attachments or modifications
Modifications and rework (additional threads or bore holes) or
attaching fittings that are not offered as accessories by SCHUNK
may be performed only with permission of SCHUNK. This also
applies to the installation of safety devices.
2.5 Personnel qualification
Assembly and disassembly, commissioning, operation and repair of
the chuck may be performed only by qualified specialists who have
been instructed with respect to safety.
All persons who are assigned to operate, maintain and repair our
chuck must have access to the operating manual, especially the
chapter “Fundamental safety instructions”. We recommend that
the operator create in-house safety operating instructions.
Persons in training may be assigned to machines and technical
equipment in which a chuck is mounted only if they are under the
constant guidance and supervision of qualified specialists.
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Basic safety instructions
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2.6 Organizational measures
Obeying the rules
Via suitable organizational measures and instructions, the
operator must ensure that the relevant safety rules are obeyed by
the persons asked to operate, maintain and repair the chuck.
Checking the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards mounted on the machine where the chuck is mounted are
clearly legible and are observed.
Faults
If a fault occurs on the chuck and this fault endangers safety or if a
problem is suspected due to production characteristics, the
machine tool where the chuck is mounted must be immediately
stopped and remain shut down until the fault has been located
and remedied. Only allow specialists to remedy faults.
Spare parts
Only ever use original SCHUNK spare parts.
Environmental regulations
Comply with the applicable legal norms when disposing of waste.
2.7 Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).

Warranty
3 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the applicable documents, }1.2 [/6]
• Observe the ambient conditions and operating conditions
• Observe the maximum number of clamping cycles }6.1 [/18]
• Observe the specified maintenance and lubrication
intervals, }9 [/30]
Parts touching the workpiece and wear parts are not included in
the warranty.
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Torques per screw
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4 Torques per screw
Tightening torques for mounting screws used to clamp the chuck
on lathes or other suitable technical equipment (screw quality
10.9)
Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Admissible torque
MA (Nm)
13 28 50 88 120 160 200 290 400 500 1050 1500
Tightening torques for mounting screws used to attach top jaws
onto the chuck (screw quality 12.9)
Screw size M6 M8 M10 M12 M14 M16 M20 M24
Max. admissible torque MA (Nm) 16 30 50 70 130 150 220 450

Scope of delivery
5 Scope of delivery
Centering chuck (complete) ROTA-S plus 2.0 or ROTA-S plus
1 Console plate
3 Extensions of guideway
1 Set of long special base jaws
1 Set of short special base jaws
1 Cover plate
2 Centering bolts Ø 32g6 / Ø 50g6
Screws and T-nuts for mounting on the machine table
1 Allan key (up to size 1200 only)
1 Ratchet with adapter
1 Operating Manual ROTA-S flex
1 Operating Manual ROTA-S plus 2.0 or ROTA-S plus
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Technical data
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6 Technical data
6.1 Chuck data
(with long base jaws)
ROTA-S flex 550 700 1000 1200 1400
Max. torque Nm 120 220 280 320 350
Stroke per jaw mm 7 9.7 12 12 15
Recommended max. speed min-1 1000 800 500 500 400
Total gripping force max. kN 100 180 230 270 270
Mass moment of inertia kg m21.6 7.078 25.03 57.89 125.28
Chuck through hole mm 52 92 102 162 252
Weight with jaws kg 65 150 360 490 830
Centrifugal torque of the long
base jaws
McGB kgm 0.153 0.5448 1.8 2.66 5.59
Max. jaw center eccentricity in
axial direction (with long base
jaws)
amax mm For the ROTA-S flex chucks it's necessary to
determine those data specific. Calculation
examples are in the chapter "Technology" in
the SCHUNK-lathe-chuck-catalog or in the
chapter "Special jaws/Technology" in the
SCHUNK-power-chuck-catalog. Those catalogs
are also available as download at
www.de.schunk.com.
The recommended max. speed is only valid for max. operating
force and the use of the suitable hard standard stepped jaws.
Warranty and maximum clamping cycles
Length of warranty 24 Months
Maximum clamping cycle number 50 000 Cycles
When using unhardened top jaws or jaws in special design, make
sure that their weight is as low as possible
For soft top jaws or jaws in special design the permissible speed of
the respective cutting task has to be calculated in accordance to
VDI 3106, whereby the maximum standard value may not be
exceeded. The calculated values have to be examined with a
dynamic measurement. Control of function (piston movement and
actuation pressure) has to be accomplished in accordance with the
guidelines of the professional association.
The recommended speed is valid for ROTA-S flex with long base
jaws and SCHUNK stepped block jaws, hard, type STF.
In this the base jaws are inserted flush with outer diameter of the
chuck.

Technical data
Jaw type SFA 200 SFA 315 SFA 400 SFA 500 SFA 630
Weight / Set [kg] 2.0 5.6 13.5 13.5 40.0
The speed of rotation must be reduced for jaws with a higher
weight!
Max. oscillating diameter – with base jaws type SFG
ROTA-S flex 550 700 1000 1200 1400
Oscillating diameter Ø [mm] 570 755 1000 1265 1400
The chuck is balanced at Q 6.3 at rated speed.
6.2 Clamping force / speed diagrams
The diagrams relate to a 3-jaw chuck.
Clamping force/RPM curves have been calculated using long, hard
base jaws and hard SHF and SFA standard jaws. During this the
maximum actuating force was applied.
The diagrams showing short, hard base jaws and hard SHF and SFA
standard jaws can be found in the ROTA-S plus or ROTA-S plus 2.0
operating manuals contained in the scope of delivery
The chucks were in perfect condition and lubricated with SCHUNK
LINOMAX special grease.
After modification of one or several of these prerequisites the
diagram will no longer be valid.
Chuck setup for clamping force/RPM diagram
Measuring point
F / 3 Clamping force per jaw S Center of gravity
rsCenter of gravity radius amax Max. jaw center of gravity
eccentricity in axial
direction
Fmax Actuating force
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Technical data
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ROTA-S flex 550 (with long jaws)
ROTA-S flex 700 (with long jaws)
ROTA-S flex 1000 (with long jaws)